FOOD & BEVERAGE INDUSTRY FOCUS INTEGRATION IS ALL PART OF THE MASTER PLAN
materials, equipment and quality test specifications, all of which are particularly important in the food and beverage sector. Environmental factors such as trade
instability, tightening industry standards and changing consumer preferences mean that manufacturers must ensure their MES is effective and secure to allow swift adaptation to new challenges. The full integration of systems allows
Darcy Simonis, Industry Network Leader for ABB, explores how a single integrated system architecture can benefit plant operators by synchronising applications and devices in the manufacturing process
M
any food and beverage plants have incrementally upgraded their
systems over the years, with them now being a complex network of distributed control systems (DCSs) and supervisory control and data acquisition (SCADA) systems. Connecting a mix of DCS and SCADA systems into one master system can have multiple benefits. The first SCADA systems were
independent, with no connectivity to other systems and were traditionally used for operating and monitoring production in a plant. Modern systems can remotely monitor and control operations with coded signals over communication channels and log data for auditing purposes. The importance of collecting, storing
and analysing data is crucial, but this increase in data raises new questions of cybersecurity. If systems are not maintained and software becomes outdated, SCADA-based systems can be left open to vulnerabilities. For this reason, operators should regularly review their systems to protect them against cyber-attacks. With an increasing amount of data, a
DCS system can process a large amount of current information, however the failure of one controller affects more than one loop and requires a skilled operator to minimise downtime. In the food industry, any period of downtime can have catastrophic effects and can result in lost production. With new challenges faced by SCADA and DCS systems, unifying all
operations into one master system is key to improving efficiency. Coupled with technological
advancements, rapidly changing consumer demands in the food and beverage industry have forced manufacturers to adapt quickly to retain a competitive edge. Consumers expect traceability throughout the entire supply chain, meaning the need for real-time continuous data is essential. Digital transformation in the food industry continues to be driven by these two key trends. So, what do these shifts mean and how can a move towards an integrated digital operating environment benefit food manufacturers? Unifying control systems into one fully
integrated system provides the synchronisation of all applications and devices involved in the manufacturing process. This allows for the successful merging of information flow from DCS and SCADA systems, so that it is available in one interface in real-time. And one of the best means of unifying these communications is by using a single industrial software system. ABB’s Manufacturing Execution System
(MES) allows users to optimise plant manufacturing and maintenance as well as a host of other benefits. These include powerful data analysis, improved quality, targeting areas for efficiency improvement and business-wide visibility. ABB’s system allows users to visualise pending tasks, work instructions,
With many food and beverage companies now embracing an integrated plant management system, manufacturers will be able to satisfy new laws on ingredients labelling
actionable information to be available in real-time to operators, often across multiple plants. Greater control and visibility of data improves security and allows for targeted improvements to processes. It also makes digital twinning feasible, where plant managers simulate plant operations virtually to achieve full plant visualisation, support proactive maintenance and aid the decision-making process, not only from an operational but also from a cost-cutting perspective. Secure reliable processing and an
increase in manufacturing flexibility can boost efficiency and productivity, letting users optimise plant manufacturing and maintenance to the maximum. The food industry has been hit with
numerous safety scandals, resulting in former UK Environment Secretary Michael Gove announcing a new law that will require manufacturers to include full ingredients labelling on pre-packaged foods from 2021. Working to rigorous industry standards,
key regulations and new manufacturing practices is vital. Plant managers in the food and beverage sector can improve the safety and quality of their operations, reduce unplanned downtime and mitigate food emergencies by viewing all data points in one place. Faster reactions to any manufacturing process anomalies can improve quality standards which also cuts down on wasted ingredients. An integrated master system also allows
for a shorter time to market for new products due to less delay. If less stock is held up at different stages of the process, this can reduce inventory levels and help raise quality standards. The successful integration of all systems
in the manufacturing process means that plant operators can leverage the diverse capabilities of each system to improve productivity, cost-effectiveness, meet price competition, launch innovative products, and enter new markets. The consideration of multiple data sets with interconnected factors allows for business- wide improvement, which is essential in the current climate.
ABB
www.abb.com
PROCESS & CONTROL | DECEMBER 2019/JANUARY 2020 29
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